Method and system for joining stator wires

ABSTRACT

A method and system is provided to join the wire ends of a stator by placing a crimpable element on a wire end pair such that the wire ends of the wire end pair are surrounded by the crimpable element, and deforming the crimpable element using a crimping tool to form a crimped joint. The crimped joint is configured to provide an electrical connection between the wire ends of the wire end pair. The wire ends may be retained in substantial contact with each other by the crimpable element. The wire end portion of the stator may be immersed in a molten solder bath to form a solder joint joining the wire end pair comprising a crimped joint. The stator may be configured as a bar pin stator including a plurality of bar pins defining the wire ends.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. patent application Ser. No.13/094,880 filed on Apr. 27, 2011, which is hereby incorporated byreference in its entirety.

TECHNICAL FIELD

The present invention relates to a method and system for joining thestator wires of electric devices.

BACKGROUND

Electric devices such as motors and generators having a stator securedwithin a housing of the motor/generator are well known. A rotor mountedon a shaft is coaxially positioned within the stator and is rotatablerelative to the stator about the longitudinal axis of the shaft totransmit the force capacity of the motor. The passage of current throughthe stator creates a magnetic field tending to rotate the rotor andshaft.

Some stators are generally configured as an annular ring and are formedby stacking thin plates, or laminations, of highly magnetic steel. Acopper winding of a specific pattern is configured, typically in slotsof the lamination stack, through which current is flowed to magnetizesections of the stator assembly and to create a force reaction thatcauses the rotation of the rotor.

Bar pin stators are a particular type of stator that include a windingformed from a plurality of bar pins, or bar pin wires. The bar pin wiresare formed from a heavy gauge copper wire with a rectangular crosssection and generally configured in a hairpin shape having a curvedsection and typically terminating in two wire ends. The bar pins areaccurately formed into a predetermined shape for insertion into specificrectangular slots in the stator, and are typically coated with aninsulating material prior to insertion, such that the adjacent surfacesof the pins within the slots are electrically insulated from each other.

Typically, the curved ends of the bar pins protrude from one end of thelamination stack and the wire ends of the bar pins protrude from theopposite end of the lamination stack. After insertion, the portions ofthe wire protruding from the lamination stack are bent to form a complexweave from wire to wire, creating a plurality of wire end pairs.Adjacent paired wire ends are typically joined to form an electricalconnection by welding one wire end to its adjacent or paired wire end toform a welded joint, where each pair of wires is individually welded,for example, by arc welding. The resultant weave pattern and pluralityof welded joints determines the flow of current through the motor. Tofacilitate welding of the wire ends, the wire ends of the bar pins aretypically stripped of insulation prior to insertion into the laminationstack and bending into the weave pattern. Electrical conductivity andstructural integrity of the welded joint between each of the paired wireends is a key determiner of motor quality and performance. Joint qualitycan be affected by the geometry of the wire ends, cleanliness of thewire surfaces prior to welding, defects such as porosity and microcracksintroduced into the weld, spatter produced in the arc welding process,the cross-sectional or surface area of the weld and other factors. Jointquality can also be affected by variation in the positioning of theadjacent wire ends as a result of the bending process, where spacing andproximity of the wire ends to each other may contribute to variabilityin the welded joint. Frequent tooling adjustment or limited tool lifemay be required during the wire bending process to maintain the tighttolerances required to accurately position the wire ends for the weldingoperation. The process of arc welding each wire pair joint individuallyis time consuming and may produce inconsistent welded joints.Variability in the process and configuration of each wire end pairresults in variability in the electrical connection of each wire endpair. This may result in thermal variation in the operation of themotor, localized overloading of the welded joint causing an electricaldiscontinuity, e.g., a short, in the winding due to, for example, weldsof minimal surface or cross-sectional area or with a small heat-affectedzone, or due to weld splatter between wire end pairs.

SUMMARY

A method of and system for joining the wire ends of a stator assembly isprovided herein. The stator assembly may be configured as a bar pinstator including a plurality of bar pins, each bar pin including one ormore wire ends. The method includes placing a crimpable element on awire end pair of a stator assembly such that each of the wire ends ofthe wire end pair extend through a hollow portion defined by thecrimpable element. The crimpable element, which may be configured tosubstantially surround the wire end pair, may be compressed or deformedusing a crimping tool to form a crimped joint. The crimped joint may beconfigured to provide an electrical connection between the wire ends ofthe wire end pair, for example, by providing an electrically conductivecontact area between the wire ends of the wire end pair. The method maybe repeated to form a plurality of crimped joints on a plurality of wireend pairs of a stator, such that the electrical connections formed bythe plurality of crimped joints may define a current flow path through awinding of the stator assembly.

The method and system may further include immersing the wire end portionof the stator assembly in a molten solder bath, wherein the wire endportion includes the plurality of crimped joints, such that each of theplurality of crimped joints may be wetted by molten solder. A solderjoint may be formed by solidifying the molten solder wicked into thecrimped joint, wherein a solder joint thus formed may join the wire endsof the wire end pair of the respective crimped joint, thus providing anelectrical connection between the wire ends of the wire end pair.

A stator assembly is described herein, including a plurality of bar pinsconfigured to define a wire end portion including a plurality of wireends. The plurality of wire ends may be configured in a weave patterndefined by the plurality of wire end pairs, wherein each respective oneof the plurality of wire end pairs is joined by a respective crimpedjoint including a crimpable element. Each crimped joint may provide anelectrical connection between the wire ends of the wire end pairincluded in the crimped joint. The plurality of crimped joints joiningthe plurality of wire end pairs of the stator assembly may collectivelydefine a current flow path through the weave pattern of the stator.

The crimped joint provides an increased surface area to carry current ascompared with an arc welded joint, therefore improving the electricalperformance and decreasing the susceptibility of the rotor tooverloading and electrical shorts. The electrically conductive area mayinclude the contact area between the crimpable element and the wireends, and/or between the wire ends themselves, where the wire ends areretained in contact with each other by the deformed portion of thecrimped joint. The wire ends may be deformed during the crimpingoperation such that the contact area therebetween is increased ascompared to contact area between the wire ends prior to crimping and/ordeformation. The crimping process described herein may be less sensitiveto fit variation between the proximate surfaces of the wire ends beingjoined, in comparison with a welding process, due to the capability toeffectively move the wire ends into contact with each other during thecrimping process, thereby decreasing the influence of weave patternaccuracy and wire to wire fit on the electrical connection quality ofthe joint.

In a non-limiting example, the crimped joint may be immersed in a solderbath such that molten solder may be wicked into any openings remainingbetween the wire ends and/or between the wire ends and the crimpableelement in the crimped joint, to form a solder joint which may bereinforcing and/or supplemental to the crimped joint, which may furtherimprove the quality and durability of the electrical conductivity of thejoint.

The above features and other features and advantages of the presentinvention are readily apparent from the following detailed descriptionof the best modes for carrying out the invention when taken inconnection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic perspective view of a stator assembly prior tojoining the wire ends of the stator winding;

FIG. 2 is a partial schematic perspective view of the wire end portionof the stator assembly of FIG. 1;

FIG. 3 is a partial schematic illustration of a cross section of thewire end portion of the stator of FIG. 2 showing a first wire end pairreceiving a crimpable element from a crimping device, and a second wireend pair with a crimped joint formed thereon;

FIG. 4A is a cross-sectional view of section 4A-4A of the crimpableelement of FIG. 3;

FIG. 4B is a cross-sectional view of a non-crimped portion of thecrimpable element of FIG. 3;

FIG. 4C is a cross-section view of section 4C-4C of a crimped portion ofthe crimped joint of FIG. 3;

FIG. 5 is a partial schematic illustration of the wire end portion ofthe stator with a plurality of crimped joints and showing the crimpingdevice; and

FIG. 6 is a partial schematic illustration of the wire end portion ofthe stator immersed in a solder bath.

DETAILED DESCRIPTION

Referring to the drawings wherein like reference numbers represent likecomponents throughout the several figures, the elements shown in FIGS.1-6 are not to scale or proportion. Accordingly, the particulardimensions and applications provided in the drawings presented hereinare not to be considered limiting. A method and system of joining thewire ends of a stator assembly is provided. The method and systemincludes placing a crimpable element on a wire end pair of the statorassembly and compressing or deforming the crimpable element using acrimping tool to form a crimped joint. The crimped joint may beconfigured to provide an electrical connection between the wire ends ofthe wire end pair, for example, by providing an electrically conductivecontact area between the wire ends of the wire end pair. FIG. 1 shows astator assembly 10, also referred to as a stator, prior to joining ofwire ends 28 by crimping. The stator 10 is generally configured as anannular ring and includes a lamination stack 16, which is formed bystacking laminations in a specific pattern. Each lamination includes aplurality of radially distributed slots which are oriented duringassembly of the lamination stack 16 to define a plurality of generallyrectangular slots 18 which are distributed radially and extend from endto end of the stack 16.

The stator 10 is shown in FIG. 1 configured as a bar pin stator, whereina winding 12 is formed from a plurality of bar pins 24, also referred toas bar pin wires. Winding 12 may also include terminals or connections20 a, 20 b and 20 c, for connecting the various phases of the winding12. The bar pin wires 24 are typically formed from a heavy gauge, highconductivity copper wire with a rectangular cross section and each barpin wire 24 is generally configured in a hairpin shape having a curvedsection 22 and typically terminating in two wire ends 28. The bar pins24 are accurately formed into a predetermined shape for insertion intothe slots 18 in a predetermined weave pattern. The bar pins 24 aretypically coated with a layer of an insulating material 26 prior toinsertion, such that the adjacent surfaces of the bar pins 24 within theslots 18 are electrically insulated from each other. To facilitatejoining of the wire ends 28 to form an electrical connection, the wireends 28 of the bar pins 24 are typically stripped of the insulatinglayer 26 prior to insertion into the slots 18 of the lamination stack 16and prior to bending to form a weave pattern such as the weave patternshown in FIG. 1 and in additional detail in FIG. 2. Each slot 18 may belined with a slot liner 30, to insulate the bar pins 24 from thelamination stack 16, and to prevent damage to the insulating layer 26during insertion of the bar pins 24 in the slots 18.

FIG. 1 shows the curved ends 22 of the bar pins 24 protruding from oneend of the lamination stack 16 and the wire ends 28 of the bar pins 24protruding from the opposite end of the lamination stack 16. Afterinsertion, the wire ends 28 protruding from the lamination stack 16 arebent to form a complex weave from wire to wire, wherein the plurality ofbent wire ends 28 is generally referred to as the wire end portion 14 ofthe stator 10. The wire ends 28 of the bar pins 24 extending through theslots 18 are bent to a desired configuration, as shown in FIG. 1 and inadditional detail in FIG. 2, so each respective wire end 28 may bepaired with and joined to a different wire end 28 according to theconnection requirements of the winding 12, to form a plurality of wireend pairs, such as the wire end pairs 32, 42 shown in FIGS. 2 and 3.

As will be described further in detail, adjacent paired wire ends 28 arejoined to form an electrical connection by surrounding the adjacentpaired wire ends 28 with a crimpable element 70 (see FIGS. 3-4) andcompressing and/or deforming the crimpable element 70 and the adjacentpaired wire ends 28 such that one wire end is placed in contact with itspaired wire end and a crimped portion 74 (see FIG. 3) to form a crimpedjoint 80. A crimpable element 70 may be placed on each pair of wirescomprising the wire end portion 14, and individually crimped therebyforming a plurality of electrical connections. The resultant weavepattern and plurality of crimped joints 80 determines the path of thecurrent flow through the winding 12.

FIG. 2 shows, by way of non-limiting example, a representativeperspective sectional view of the weave pattern, also referred to as thewinding pattern, of the wire end portion 14 of stator 10 in additionaldetail. The collective wire ends 28 of bar pins 24 have been arranged infour layers in the slots 18 of the lamination stack 16, where theoutermost layer includes a plurality of wire ends 28 in the plurality ofslots 18 closest to the outer diameter of the lamination stack 16, andthe innermost layer includes a plurality of wire ends 28 in theplurality of slots 18 closest to the inner diameter of the laminationstack 16. As shown in FIGS. 2 and 3, the plurality of wire ends formingthe innermost or first layer of the winding 12 are identified in FIGS.2-6B as wire ends 34. The second layer of the winding 12, which isproximate to the first layer, is formed of a plurality of wire endsidentified as wire ends 36. The third layer of the winding 12, which isproximate to a fourth or outermost layer, is formed of a plurality ofwire ends identified as wire ends 44. The outermost or fourth layer isformed of a plurality of wire ends identified as wire ends 46.

FIGS. 2 and 3 show each of the wire ends 34 in the first layer is bentsuch that it is proximate to and paired with a wire end 36 in the secondlayer, to form a wire end pair 32. FIG. 3 shows a crimpable element 70being placed on the wire end pair 32 such that the wire end 34 may beheld proximate to and/or in contact with the wire end 36. The crimpableelement 70 may be deformed (as shown in FIG. 5) to form a crimpedportion 74 such that the paired wire ends 34, 36 and the crimpableelement 70 forms a crimped joint 80 providing an electrical connectionbetween the wire end 34 and the wire end 36 of the wire end pair 32,similar to the crimped joint 80 shown on the wire end pair 42 of FIG. 3.

Similarly, each of the wire ends 44 in the third layer is bent such thatit is proximate to and paired with a wire end 46 in the fourth layer, toform a wire end pair 42. A crimpable element 70 is placed on the wireend pair 42 (see FIG. 3) such that the wire end 44 is held proximateand/or in contact with the wire end 46. The crimpable element 70 isdeformed to form a crimped portion 74 such that the paired wire ends 44,46 and the crimpable element 70 forms a crimped joint 80 providing anelectrical connection between the wire end 44 and the wire end 46 of thewire end pair 42.

The wire ends 34, 36, 44, 46 may be collectively referred to as the wireends 28 (see FIG. 1), when describing the plurality of wire endscomprising the wire end portion 14.

The winding 12 may be configured to include a first winding set and asecond winding set. The first winding set may be comprised of theplurality of bar pins 24 forming the first layer of wire ends 34 and thesecond layer of wire ends 36, e.g., the first winding set may becomprised of the plurality of wire pairs 32. The second winding set maybe comprised of the plurality of bar pins 24 forming the third layer ofwire ends 44 and the fourth layer of wire ends 46, e.g., the secondwinding set may be comprised of the plurality of wire pairs 42.

As described previously, electrical current is conducted through thewinding 12 via a weave pattern established by the bar pins 24 and theplurality of crimped joints 80 including the wire ends 28. The wire endpairs are configured and bent such that each wire end pair 32, 42 isseparated circumferentially and radially from each other wire end pair32, 42 to minimize the potential for forming an electrical connectionbetween any two wire end pairs. For example, and referring to FIGS. 1, 2and 5, each wire end pair 32 is arranged in the first winding set suchthat it is separated circumferentially from an adjacent wire end pair 32by a circumferential space or interval 38, and each wire end pair 42 isarranged in the second winding set such that it is separatedcircumferentially from an adjacent wire end pair 42 by a circumferentialspace or interval 38. Referring now to FIG. 3, it is shown that eachwire end pair 32 is separated radially from an adjacent wire end pair 42by a space or interval 48, wherein the radial space or interval 48 isestablished by the radial spacing between the second layer of wire ends36 and the third layer of wire ends 44.

As shown in FIGS. 3 and 5, the crimpable element 70 is placed and/orpositioned on a wire end pair 32, 42 by a device 60 and subsequentlycrimped by a crimping tool 62 to form a crimped joint 80. The crimp tool62 may also be referred to herein as a set of crimping tools, ascrimping jaws, as a set of jaws and/or as jaws. For purposes ofillustration, the crimpable element 70 and the process of forming thecrimped joint 80 may be described relative to one or the other of thewire end pairs 32, 42, recognizing that the description is applicable toeither of the wire end pairs 32, 42, e.g., the crimpable element 70 andthe process of forming the crimped joint 80 may be substantially thesame for each of the plurality of wire end pairs 32 and each of theplurality of wire end pairs 42 comprising the wire end portion 14 of thestator 10. The crimpable element 70 may also be referred to as a crimpring.

The wire ends 28 forming the wire end portion 14 of the stator 10 areconfigured and bent such that the wire ends in each wire end pair 32, 42are positioned proximate to each other to facilitate receiving acrimpable element 70 onto each wire end pair 32, 42, such that thecrimpable element 70 operatively surrounds the two wire ends in the wireend pair. For example, and as shown in FIG. 3, the wire ends 44, 46 ofthe wire end pair 42 are positioned proximate to each other tofacilitate receiving the crimpable element 70, which may be placed onthe wire pair end 42 by a crimping device 60, as shown in FIG. 3. Thecrimpable element 70 may be positioned on the wire end pair 42 such thatthe wire ends 44, 46 extend into and/or protrude through the hollowportion 72 of the crimpable element 70, as is illustrated by FIGS. 4Aand 4B.

In a non-limiting example, the crimpable element 70 may be made of amaterial containing one or a combination of copper, brass, tin, mildsteel, aluminum, stainless steel, or zinc, and configured such that thecrimpable element 70 is deformable by a crimping tool 62 to form acrimped portion 74. The choice of material(s) comprising the crimpableelement 70 may be based on a number of factors including the formabilityof the material, e.g., the capability of the material to be deformed orcompressed by the crimping tool 62 to form a crimped portion 74 and/orthe crimped joint 80. Another factor may be the electrical conductivityof the material, where an electrically conductive path may beestablished between the crimpable element 70 and at least one of thewire ends 28 in contact with the crimpable element 70. Other factorsconsidered may include corrosion resistance of the crimpable elementmaterial, the operating environment of the stator 10, the operatingtemperature of the stator 10 and/or the wire ends 28, the current flowthrough the stator winding 12, corrosive elements including humidity andcontamination in the operating environment, etc.

The crimpable element 70 may be configured, in the non-limiting exampleshown in FIGS. 3-4C, as a generally rectangular ring having radiusedcorners, and defining an opening or hollow portion 72 as shown inadditional detail in FIG. 4A. The crimpable element 70 may be shapedsuch that the surface 78 defining the hollow portion 72 surrounds theouter periphery of the wire end pair upon which the crimpable element 70is placed, as shown in FIG. 4B for a crimpable element 70 placed on thewire end pair 42. The crimpable element 70 and/or the hollow portion 72of the crimpable element 70 may be configured to facilitate insertion orplacement on a wire end pair 32, 42, such that the crimpable element 70,as it is placed on the wire end pair 32, 42, urges or displaces the wireends toward one another, which may cause the proximate (adjacent)surfaces 56 of the wire ends to come in contact with each other, therebydefining a contact area 58. The opening 72 and/or the crimpable element70 may be tapered, flared, chamfered or configured with a lead-in orleading surface to urge the wire ends toward one another duringplacement on the wire end pair 32, 42, which may facilitate forming thecontact area 58.

The crimpable element 70 may be crimped by a crimping tool 62 configuredto form a crimped portion 74 to retain the wire ends in contact witheach other, as shown for the wire end pair 32 in FIGS. 3 and 4C, suchthat the contact area 58 thus formed may provide an electricallyconductive path between the wire ends 34, 36. The contact area 58provided by the crimped joint 80 may be significantly larger, forexample, than an electrically conductive surface area provided by awelded joint, thereby providing an increased surface area andcross-sectional area to carry electrical current as compared with thewelded joint. The increase in the current carrying area may decreasesusceptibility of the crimped joint 80 to electrical shorts or otherelectrical discontinuities, as compared with the welded joint.

Other configurations or features of the crimpable element 70 arepossible. The term “ring” is not intended to be limiting or limited to agenerally circular configuration, e.g., the crimpable element or crimpring 70 may be generally configured as an annular or cylindrical elementhaving a generally round, generally oval, or generally rectangularshape, or in any other shape which may correspond to the shape of thewire ends to be joined in the crimped joint 80. The opening or hollowportion 72 may be configured or shaped such that the surface definingthe hollow portion 72 fits snugly around the periphery of the wire endpair. A contact area 58 may be established between the wire ends as theyare displaced (snugged) together by placement of the crimpable element70 on the wire end pair 32, 42. The crimpable element 70 may beconfigured, for example, as an open-ended generally rectangular orgenerally cylindrical element, e.g., a cup shaped element (not shown)which may be fitted over the wire end pair as a cap, and subsequentlycrimped and/or deformed to form the crimped joint 80. The crimpableelement 70 may be configured as an open ring, e.g., a generally C-shapedor U-shaped element, which may be crimped to substantially surround theperiphery of the wire end pair 32, 42 and retain the wire ends 28 inoperative contact with each other to provide an electrically conductivecontact area 58 therebetween.

FIGS. 3-5 illustrate, in a non-limiting example, a method for joiningthe wire ends of the stator 10. FIG. 3 shows a crimping device 60configured to place a crimpable element 70 on a wire end pair, which inFIG. 3 is the wire end pair 42. FIG. 4A shows a cross-sectional view ofthe crimpable element 70 prior to placement on the wire end pair 42, andFIG. 4B is a cross-sectional view of a non-deformed portion of thecrimpable element 70 positioned on the wire end pair, which may be across-section view of the crimpable element 70 on the wire end pair 42prior to crimping, or may be, for example, a cross-sectional view of anon-deformed portion 74 of the crimped joint 80 including the wire endpair 32, as shown in FIG. 3. FIG. 3 further shows a crimped joint 80formed using the jaws 62 and including the wire end pair 32, and FIG. 4Cshows a cross-sectional view of the crimped portion 74 of the crimpedjoint 80 including the wire end pair 42. For simplicity and clarity ofillustration, the process of forming the crimped joint 80 may bedescribed relative to one or the other of the wire end pairs 32, 42,recognizing that the description is applicable to either of the wire endpairs 32, 42. FIG. 5 shows a schematic perspective view of the crimpingdevice 60 forming a crimped joint 80 on one of a plurality of wire endpairs 32. For simplicity and clarity of illustration, FIG. 5 shows onlythe first winding set of stator 10, consisting of wire end pairs 32. Notshown, but understood, a crimped joint 80 would be formed on each of theplurality of wire end pairs 32 and 42 comprising the wire end portion 14of the stator 10 to establish a current flow path through the winding 12of the stator 10.

As shown in FIG. 3, a crimpable element 70 is provided to the stator 10for placement on a wire end pair, which in the example shown is the wireend pair 42. A device 60 may be used to convey or transport thecrimpable element 70 to the stator 10, and to place and/or position thecrimpable element 70 such that it is received on the wire end pair 42.

The device 60 may be, as shown in the non-limiting example of FIGS. 3and 5, configured with a set of jaws 62 wherein each jaw 62 isoperatively attached to an arm 64, which may also be referred to as alever arm. The device 60 may be configured such that each of the arms 64may be movable radially inward toward an axis 68 (see FIG. 5) of thedevice 60, such that the jaws 62 may exert a compressive force on acrimpable ring 70, to hold and/or transport the crimpable ring 70 forplacement on a wire end pair 32, 42 of the stator 10. The arms 64 may bemovable radially outward from the axis 68 to release the crimpable ring70 held by the jaws 62. The jaws 62 may be configured as a set ofcrimping tools such that the device 60 may be used to form the crimpedjoint 80, e.g., the jaws 62 may be configured such that when the leverarms 64 are moved radially inward with sufficient force, the jaws 62cooperate to deform the crimpable element 70 thus forming the crimpedportion 74, as shown in the FIGS. 3 and 5. It would be understood thatthe weave pattern of the wire end portion 14, e.g., the bending patternof the wire ends 28, would be configured such that the circumferentialspaces 38 and the radial spaces 48 between the wire pairs 32, 42 are ofsufficient size (width) to receive the jaws 62 and crimpable element 70for placement of the crimpable element 70 on the wire end pair andcrimping thereof to form the crimped joint 80.

More than one device or method may be used to position and crimp acrimpable element 70 on each of the wire end pairs 32, 42. For example,a first (placing) device may be used to place and/or position acrimpable element 70 on a wire end pair 32, 42, and a second (crimping)device may be used to crimp the crimpable element 70. The placing devicemay be configured similar to the device 60 shown in FIGS. 3 and 5, ormay be of another configuration. The method used to place the crimpableelement 70 may be automated, manually controlled, or a combinationthereof. The placing device may incorporate an integral feedingmechanism to provide a continuous supply of crimpable elements 70. Thecrimping device may be configured similar to the device 60 shown inFIGS. 3 and 5, or may be of another configuration. The method used tocrimp the crimpable element 70 may be automated, manually controlled, ora combination thereof. The device or devices 60 used to transport,place, position and/or crimp the crimpable element 70 may be controlledhydraulically, electrically, pneumatically, mechanically, or by othersuitable means. The device or devices 60 may be in operativecommunication with one or more sensors and or controllers which may beconfigured to manipulate, monitor and/or control the device or devices60 and the crimping process described herein.

The wire ends 44, 46 comprising the wire end pair 42 shown in FIG. 3 arepositioned during the bending operation forming the wire end portion 14such that the wire ends 44, 46 are sufficiently adjacent to each otherto receive the crimpable element 70 thereon. The proximate sides orsurfaces 56 of the adjacent wire ends 44, 46 may be separated by a gap54. The configuration of the gap 54, for example, the width of the gap54, may vary due to variation in the process used to bend or orient thewire ends 44, 46 into a position in the weave pattern forming the wireend portion 14, or may vary due to variation in the size, surfaceprofile or shape of each of the wires ends 44, 46 comprising the wireend pair 42. The wire ends 44, 46 may be positioned as a result of thebending process such that the proximate surfaces 56 are in contact witheach other, to form a contact area 58. The size and configuration of thecontact area 58 may vary based on the relative position of the proximatesurfaces 56 and the configuration or profile of each of the proximatesurfaces 56.

Referring again to FIG. 3, a crimpable element 70 may be providedbetween the jaws 62, and the jaws 62 may be moved radially inward withsufficient compressive force to retain the crimpable element 70 betweenthe jaws 62, without deforming the element 70. The device 60 ismanipulated to place the crimpable element 70 on the wire end pair 42such that the wire ends 44, 46 protrude into and/or through the opening72 of the crimpable element 70, as shown in the cross-sectional view ofFIG. 4B. When positioned on the wire end pair 42, the surface 78defining the opening 72 of the crimpable element 70 surrounds the outerperiphery of the wire pair 42. Prior to crimping, the proximate surfaces56 (see FIG. 4B) of the wire ends 44, 46 are adjacent to each other andmay be separated by a gap 54, or may be positioned in contact with eachother such that a contact area 58 is formed.

The lever arms 64 may be actuated by the device 60, in a non-limitingexample, to move the jaws 62 radially inward, thus increasing thecompressive force on the crimpable element 70 positioned on the wire endpair 42. As the crimping jaws 62 are progressively moved radiallyinward, sufficient force is exerted by the crimping jaws 62 on thecrimpable element 70 such that the crimpable element 70 begins to deformand become compressed against the periphery of the wire ends 44, 46,displacing the wire ends 44, 46 toward each other. As the crimpableelement 70 is compressed to form the crimped portion 74 and to push thewire ends 44, 46 together, the gap 54 between the proximate surfaces 56of the wire ends 44, 46 is substantially reduced and/or eliminated andthe contact area 58 is formed and/or increased in size (area), formingan electrically conductive path or joint between the wire ends 44, 46.

As shown in FIG. 4C, the interior surface 78 in the crimped portion maybe in direct contact with the periphery of the wire ends 44, 46, suchthat an electrically conductive path may be established between one orboth of the wire ends 44, 46 and the crimped portion 74. In thisconfiguration, the surface area available to conduct electrical currentthrough the crimped joint 80 includes the contact area 58 formed betweenthe proximate surfaces 56, and may further include the area of contactbetween the wire ends 44, 46 and the surface 78 of the crimped portion74. Additionally, the crimped joint 80 may be more resistant toseparation or degradation due to, for example, vibration, or thermalexpansion and contraction due to changes in operating temperature, ascompared to a welded joint.

The electrical current in a welded joint (not shown) may be passed onlythrough the fused area of the weld comprised of parent metal from thewire ends, which can be of variable size and susceptible to weldingdefects including porosity, microcracks, and contamination, or may be anarea of variable cross-section due to poor fit between the wire ends ineach wire end pair during welding, which may reduce the current carryingcapacity of the welded joint. A smaller sized weld may be susceptible tooverloading during current loading, causing weld failure and shortingthe electrical circuit within the winding. Accordingly, a crimped jointsuch as the joint 80 provides a greater current carrying area through afirst current path defined by the contact area 58 between the proximatesurfaces 56 of the wire ends 34, 36 (see FIG. 3), and through asecondary current path which may be provided by the crimped portion 74in contact with the periphery of the wire ends 34, 36 (see FIG. 4C),thereby providing improved electrical performance, enhanced currentcarrying capacity and decreased susceptibility of the stator 10 tooverloading and electrical shorts.

Using a crimped joint, such as joint 80, to provide the electricalconnection between the wire ends 34, 36 is further advantaged by adecreased sensitivity to the configuration of the wire end pair 32, andspecifically, to the gap 54 or spacing between the proximate surfaces56. Whereas the ability to form a weld between the wire endsdeteriorates as the gap 54 between the proximate surfaces 56 of the wireends 34, 36 increases, the crimpable element 70 surrounds the peripheryof the wire ends 34, 36 and the crimping of the crimpable element causesdisplacement of the wire ends 34, 36 toward each other to substantiallyreduce the gap 54 and form or increase an electrically conductivecontact area 58.

As shown in FIG. 3, the crimped joint 80 may be formed such that one ormore portions 76 of the crimpable element 70 may be only minimallydeformed, or may not be deformed at all. The cross-section of theminimally or not deformed portion 76 may be configured as shown in FIG.4B, where a gap 54 may remain between the wire ends or between theperiphery of the wire end pair and the interior surface 78.

After completing the crimping process, e.g., forming the crimped joint80, the jaws 62 may be moved radially outward such that the device 60may be removed from the crimped joint 80. The crimping process may berepeated to form a crimped joint 80 on each of the plurality of wireends 32, 42 of the wire end portion 14 of the stator 10. The pluralityof crimped joints 80 thus formed may collectively define a current flowpath through the weave pattern of the stator 10.

The crimping process may be controlled by any suitable method to providea crimped portion 74 defining a crimped joint 80. By way of non-limitingexample, the compressive force exerted by the jaws 62 on the crimpableelement 70 may be measured, monitored and/or controlled to a specifiedforce correlated to provide certain characteristics or features of thecrimped joint 80. For example, the crimping force may be correlated to adensity percentage of the crimped joint 80 measured in a cross-sectionof the crimped portion 74, where the density percentage of thecross-section could be correlated to the electrical conductivity of thejoint to establish a minimum crimping force required to form anacceptable crimped joint, e.g., one capable of providing an electricallyconductive path through the crimped joint 80.

As another example, the closing (inward) movement of the crimping tool62 to a predetermined position may be measured, monitored and/orcontrolled, where the closed position may be correlated to providecertain characteristics or features of the crimped joint 80, and tocontrol the crimping process. For example, the position of the crimpingjaws 62 with respect to each other or to the axis 68 of the device 60may correlate to a dimension X′ (see FIG. 4C), where dimension X′corresponds to the amount of deformation of the crimped portion 74required to achieve a minimum density percentage correlated to theelectrical conductivity of the crimped joint 80. For example, it may bedetermined that for a combination of a wire end pair comprised of wireends 44, 46 and a crimpable element 70 of dimension X (see FIG. 4B),that deformation of the crimpable element 70 using jaws 62 causingcompression of the dimension X to a smaller dimension X′ forms anacceptable crimped joint 80. The dimension X′ may be correlated tomovement of the jaws 62, movement of the lever arms 64, or bymeasurement during the crimping process by the device 60 or otherwise.

In yet another example, the configuration of the crimped joint 80 may bemeasured, monitored and/or controlled to control the crimping process toproduce an acceptable crimped joint 80. For example, the crimping jaws62 may be shaped to provide a specified profile of the crimped portion74, where the profile, e.g., the configuration of the crimped portion 74is correlated to the electrical conductivity of the crimped joint 80.Controlling the configuration of the crimped portion 74 may includecontrolling the height, width, depth, cross-sectional profile, or othershape features of the crimped portion 74, which may be done bycontrolling the configuration of the jaws 62 used to form the crimpedportion 74, by gauging and/or inspecting the crimped joint 80, bymonitoring the wear of and/or measuring the jaws 62, or by othertechniques understood by those skilled in the art of crimping. It wouldbe understood that the crimping operation may be controlled bycontrolling one or more of the factors and/or process characteristics orproduct features, as previously described, which may be controlledseparately or in combination and in relation to each other.

In a non-limiting example shown in FIG. 6, the wire end 14 including theplurality of crimped joints 80 may be immersed in a solder bath 50 suchthat molten solder 52 may be wicked into any openings or gaps remainingin any of the crimped joints 80, to form a solder joint which may bereinforcing and/or supplemental to the crimped joint 80 to furtherimprove the quality and durability of the electrical conductivity of thejoint 80. The solder bath 50 may contain a quantity of molten solder 52.The solder 52 may be of any solder material, such as a tin-based solder,suitable for soldering of copper wire or material(s) used to form thebar pins 24. For simplicity and clarity of illustration, FIG. 6 showsonly the first winding set of stator 10, consisting of a plurality ofcrimped joints 80 including the wire pairs 32. Not shown, butunderstood, the entire wire end portion 14 consisting of a plurality ofcrimped joints 80 formed on wire end pairs 32 and 42 would be immersedinto the molten solder 52.

The process of immersing the wire end portion 14 into the molten solder52 to allow wicking of the molten solder into any gaps in the crimpedjoints 80 may be controlled by controlling one or more factors, whichmay be controlled separately or in combination and in relation to eachother. For example, the duration of immersion of the wire end portion 14in the molten solder 52 may be controlled to a predetermined time, toensure adequate wetting of the crimped joints 80 and/or the wire endpairs 32, 42 with molten solder 52, and wicking of molten solder 52 intoany gap 54 between the proximate surfaces 56 of the wire ends 28 and/orbetween the wire ends 28 and the interior surface 78 of the crimpableelement 70. Referring to FIG. 3 and FIG. 4B, such gaps may remain, forexample, between the wire ends of the wire end pairs 32, 42 in theportions 76 of the crimpable element 70. The portions 76 may beminimally deformed or not deformed during the crimping process, suchthat the cross-section of the portions 76 may resemble the cross-sectionshown in FIG. 4B, which may include one or more gaps 54 between theperiphery of the wire ends 28 and the interior surface 78 of the portion76, or between the proximate surfaces 56 of the wire ends. The moltensolder 52 may wick into these gaps or areas, and solidify upon removalof the wire end portion 14 from the solder bath 50 to form solder jointswithin the crimpable joint 80. As another example, the depth ofimmersion of the wire end portion 14 in the molten solder 52 may becontrolled such that the wire end portion 14 is immersed to a depth d,as shown in FIG. 6. The depth d may be determined based on theconfiguration of the wire end 28, e.g., the surface area from which theinsulation 26 has been stripped or otherwise removed to define thestripped wire end 28. The depth d may be determined based on otherfactors, such as an optimized depth to allow wicking and wetting ofmolten solder 52 on the wire ends 28 in the minimally deformed portion76 of the crimped joint 80, and/or to prevent application of the moltensolder 52 to other areas or surfaces of the stator 10, such as theinsulated portion of the bar pins 24 or the lamination stack 16.

By way of non-limiting example, the stator 10 may be moved by a robot toimmerse the wire end portion 14 into and out of the molten solder 52 ata predetermined cycle or interval, where the depth of immersion of thewire end portion 14 in the molten solder 52 may be controlled, forexample, by controlling the height of the conveyor or movement of therobot using the non-limiting examples previously discussed, such thatthe wire end portion 14 is immersed to the depth d.

Other factors, such as the temperature and viscosity of the moltensolder 52 may be controlled to predetermined values, to facilitate eachof the plurality of crimped joints 80 and wire ends 28 included thereinbeing wetted by molten solder sufficiently to form a solder joint withinany gaps remaining in the crimped joint 80, and to form solder jointshaving structural integrity and configured to provide an electricalconnection between the wire ends in the respective wire end pair.

While the best modes for carrying out the invention have been describedin detail, those familiar with the art to which this invention relateswill recognize various alternative designs and embodiments forpracticing the invention within the scope of the appended claims.

1. A method of joining the wire ends of a stator assembly, the methodcomprising: placing an uncrimped crimpable element on a wire end pairsuch that each of the wire ends of the wire end pair extend into ahollow portion defined by the crimpable element to retain the wire endsof the wire end pair in proximate contact with each other, wherein thewire end pair is one of a plurality of wire end pairs configured in astator assembly; and compressing the uncrimped crimpable element using acrimping tool to form a crimped joint, wherein the crimped joint isconfigured to provide an electrical connection between the wire ends ofthe wire end pair.
 2. The method of claim 1, further comprising: placinga respective uncrimped crimpable element on a respective wire end pairof a plurality of wire end pairs configured in the stator assembly, suchthat each of the wire ends of the respective wire end pair extend into ahollow portion defined by the respective crimpable element; andcompressing each respective uncrimped crimpable element using a crimpingtool to form a respective crimped joint configured to provide anelectrical connection between the wire ends of each respective wire endpair, thereby forming a plurality of crimped joints.
 3. The method ofclaim 2, wherein the plurality of crimped joints collectively define acurrent flow path through a winding of the stator assembly.
 4. Themethod of claim 2, further comprising: immersing a wire end portion ofthe stator assembly in a molten solder bath, wherein the wire endportion includes the plurality of crimped joints, such that each of theplurality of crimped joints is wetted by molten solder; and solidifyingthe molten solder to form a solder joint in at least one of theplurality of crimped joints, wherein the solder joint provides anelectrical connection between the wire ends of said at least one of theplurality of crimped joints.
 5. The method of claim 1, whereincompressing the crimpable element includes deforming the crimpableelement and the wire ends to define an electrically conductive contactarea between the wire ends of the wire end pair.
 6. The method of claim1, wherein the stator assembly is configured as a bar pin statorincluding a plurality of bar pins, each bar pin including one or morewire ends.
 7. The method of claim 1, wherein compressing the crimpableelement includes forming a crimped portion defining the crimped joint.8. The method of claim 7, wherein the electrical connection is providedbetween a wire end of the wire end pair and at least one of the otherwire end of the wire end pair and the crimped portion of the crimpableelement.
 9. The method of claim 1, wherein compressing the uncrimpedcrimpable element using the crimping tool further comprises at least oneof: controlling the crimping force exerted by the crimping tool on thecrimpable element; controlling the crimping movement of the crimpingtool; and controlling the configuration of the crimped joint.
 10. Themethod of claim 1, wherein the crimping tool is configured to partiallydeform the crimpable element to form a crimped portion intermediate afirst nondeformed portion and a second nondeformed portion of thecrimpable element.
 11. A stator assembly comprising: a plurality of barpins configured to define a wire end portion including a plurality ofwire ends; wherein the plurality of wire ends are configured in a weavepattern defining a plurality of wire end pairs; wherein each respectiveone of the plurality of wire end pairs is joined by a respectivecrimpable element to form a respective crimped joint; and wherein therespective crimped joint provides an electrical connection between thewire ends of the respective one of the plurality of wire end pairs. 12.The stator assembly of claim 11, wherein the crimped joints of theplurality of wire end pairs collectively define a current flow paththrough the weave pattern.
 13. The stator assembly of claim 11, whereinthe respective crimped joint is configured to retain the wire ends ofthe respective one of the plurality of wire end pairs in substantialcontact with each other.
 14. The stator assembly of claim 11, whereinthe crimped joint of each respective one of the plurality of wire endpairs is defined by a crimped portion; and wherein the electricalconnection is formed in each respective one of the plurality of wire endpairs between one wire end of the wire end pair and at least one of theother wire end of the wire end pair and the crimped portion.
 15. Thestator assembly of claim 11, wherein the crimped joint of eachrespective one of the plurality of wire end pairs is defined by acrimped portion intermediate a first nondeformed portion and a secondnondeformed portion of the crimpable element.